EP2822913B1 - Procédé continu de fabrication d'un materiau à base de liant hydraulique allegé par expansion - Google Patents

Procédé continu de fabrication d'un materiau à base de liant hydraulique allegé par expansion Download PDF

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Publication number
EP2822913B1
EP2822913B1 EP13708205.3A EP13708205A EP2822913B1 EP 2822913 B1 EP2822913 B1 EP 2822913B1 EP 13708205 A EP13708205 A EP 13708205A EP 2822913 B1 EP2822913 B1 EP 2822913B1
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EP
European Patent Office
Prior art keywords
pump
composition
pore
forming agent
mixing
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EP13708205.3A
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German (de)
English (en)
French (fr)
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EP2822913A1 (fr
Inventor
Hubert Selinger
Wolfram Maier
Claude Da Silva
Marianne ALBERT
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Saint Gobain Weber SA
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Saint Gobain Weber SA
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/02—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions without using driven mechanical means effecting the mixing
    • B28C5/026—Mixing guns or nozzles; Injector mixers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/02—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00146—Sprayable or pumpable mixtures

Definitions

  • the present invention relates to the field of lightened mortars for the facade and the floor. It relates more particularly to a method of continuous application by pumping a mortar based on a lightened material, an application device used in said process and the use of this device.
  • the facade mortars layered on walls have a triple function of waterproofing, uniformity of said walls and aesthetic finish of the facades. They consist mainly of a mortar tempered with water and deposited in a thick layer before curing and drying. Soil mortars allow the realization of screeds and especially as self-leveling floor coatings. The deposition of these mortars can be achieved by pneumatic projection using a mortar pump.
  • Lightened mortars compatible with projection use are currently widely used.
  • the projection application makes it possible to deposit layers of thickness of at least a few millimeters to a few centimeters, to perfectly match the geometry of the support, and saves time compared to traditional manual methods.
  • Cementitious materials such as concretes, cements or mortars with lightening of the load are particularly appreciated because they have in particular good properties of thermal insulators. Being lighter, they exert less stress on the supports on which they are applied.
  • the amount of solid pore-forming compounds must be limited since the expansion of the mortar takes place in the chamber of the mixing pump: if the expansion is too rapid and too important, the foamed mortar occupies a too large volume and goes back to the dry mortar supply lines of the pump.
  • Requirement WO 2007/134349 discloses a process for producing expanded inorganic foams using a 15-35% solution of hydrogen peroxide as blowing agent and a suitable catalyst to control foam formation under normal temperature and pressure conditions, regardless of pH.
  • Requirement DE 10 2008 058641 A1 discloses a process in which a magnesium oxide powder, a magnesium chloride solution and a hydrogen peroxide solution are introduced continuously or discontinuously into the mixing chamber.
  • the present invention provides a method for generating large amounts of pores in a material directly during its manufacture in a projection device, continuously. Expansion of the material occurs in-situ during application.
  • expanded lightening material refers to a material whose density has decreased by in situ oxygen generation in the material.
  • tempered composition refers to a composition when mixed with mixing water, in the form of a paste, with a creamy texture, which can be used as a coating.
  • the method according to the present invention advantageously makes it possible to obtain in-situ, in the projection device, the formation of a lightened material by expansion.
  • the expansion of the material takes place directly during its projection on the support.
  • the chemical decomposition of the pore-forming agent makes it possible to continuously generate a large quantity of pores during the mixing step.
  • the accelerated reactivity, on the one hand by the presence of the catalyst and, on the other hand, by the fact that the pore-forming agent is contained in a liquid solution makes it possible to expand the material continuously. It is indeed necessary that the expansion of the material is done quickly, in a controlled manner, and is completed once the material is projected on the support.
  • This control is possible in particular by choosing the pore-forming agent concentration in the aqueous solution, the amount of catalyst present and the ratio between the flow rate of the tempered material and the flow rate of the aqueous solution comprising the peroxide-based pore-forming agent, and the mode of introduction of the blowing agent into the process.
  • the composition intended to be applied is initially in the form of a powdery composition, and comprises at least one hydraulic binder.
  • hydraulic binders are binders that irreversibly bind when they come into contact with water and harden by developing mechanical strengths.
  • the hydraulic binder content in the composition may vary from 5 to 100% by weight, preferably from 50 to 95% by weight, depending on the end use chosen.
  • composition may further comprise other binders such as inorganic binders based on calcium sulphate or on the basis of silicates, aerial lime, or organic binders for example based on resins.
  • binders such as inorganic binders based on calcium sulphate or on the basis of silicates, aerial lime, or organic binders for example based on resins.
  • the composition contains aggregates, aggregates and / or sands, and is commonly referred to as mortar or concrete depending on the size of aggregates. These compounds play in particular on the rheology, the hardness or the final appearance of the product. They are generally formed of siliceous, calcareous and / or silico-calcareous sands.
  • the content of such aggregates, aggregates and / or sands in the composition used according to the process of the present invention conventionally varies from 0 to 90% by weight, preferably from 0 to 50% by weight, relative to the total weight of the composition.
  • the composition may also comprise components called fillers, limestone or siliceous, the content of which is generally between 0 and 30% by weight relative to the total weight of the composition.
  • the total sum of binders and fillers is usually between 5 and 100% by weight, preferably from 50 to 100% by weight, relative to the total weight of the composition.
  • the composition may also contain additives and adjuvants conferring particular properties.
  • additives and adjuvants conferring particular properties.
  • rheological agents water-retaining agents, air-entraining agents, thickeners, biocidal protective agents, dispersing agents, pigments, accelerators and / or retarders, as well as other agents for improving setting, hardening, stability of the products after application and in particular for adjusting the color, workability, implementation or impermeability.
  • the content of additives and adjuvants may vary between 0.1 and 10% by weight relative to the total weight of the composition.
  • the composition may also contain lightening fillers, such as for example expanded vermiculite and / or expanded perlite and / or expanded glass or polystyrene, aerogels, or even vegetable fibers, with a content preferably of less than 15%. weight relative to the total weight of the composition.
  • lightening fillers such as for example expanded vermiculite and / or expanded perlite and / or expanded glass or polystyrene, aerogels, or even vegetable fibers, with a content preferably of less than 15%. weight relative to the total weight of the composition.
  • the composition may also be a lightened mortar as described in the application WO 2010/097556 filed in the name of the Applicant.
  • This type of lightened mortar comprises a hydraulic binder and at least 75% by volume of thermally insulating additives in the form of beads, for example expanded polystyrene.
  • These formulations may not include aggregates, aggregates and / or sands.
  • the composition is kneaded with the mixing water until a paste is obtained.
  • the mixing ratio corresponding to the ratio between the weight of water and the weight of the pulverulent composition is chosen according to the desired application.
  • the composition is spoiled in the mixing pump.
  • the composition is spoiled upstream of the kneading pump, by a continuous or discontinuous step.
  • the mixing can be done in a device different from that used for the application of lightened material.
  • the tempered composition is then sent to the kneading pump of the spraying device.
  • the mixture of the aqueous solution comprising the blowing agent with the composition comprising a hydraulic binder takes place in the outlet pipe of the kneading pump.
  • the homogenization of the various constituents is advantageously carried out in said pipe with the aid of a static mixer placed inside this pipe.
  • the mixture between the composition comprising the hydraulic binder and the solution containing the blowing agent can also take place in the kneading pump, the latter performing the homogenization.
  • the addition of the aqueous solution containing the blowing agent can be carried out in the feed pipe for introducing the mixing water into the mixing pump.
  • the support on which the material obtained is applied is any support known to those skilled in the art. Depending on the support and the desired application, the skilled person will adapt the composition of the powder mixture, as well as the mixing rate.
  • the pasty product obtained after mixing is generally stored in a hopper and is then propelled by the pump into a pipe that feeds a projection lance.
  • the pumping rate of the pump is therefore related to the product discharge rate.
  • the expansion of the dough thus obtained corresponds to the formation of the lightened material. According to the method of the present invention, this expansion is carried out by addition, in the projection device, continuously of an aqueous solution comprising a pore-forming agent based on peroxide, in the presence of a catalyst.
  • the decomposition reaction of the peroxide-based blowing agent carried out in the presence of the catalyst is an exothermic disproportionation reaction producing oxygen and water.
  • the catalyst may be mixed with the powdery material composition. It can also be mixed in the paste obtained, after mixing. It is also possible to dissolve the catalyst in the mixing water, or in the aqueous solution containing the catalyst-based pore-forming agent, provided that the pH is less than 5.
  • the addition of catalyst is carried out in the outlet line of the kneading pump.
  • Mention may be made, for example, as a catalyst, of salts and oxides of manganese, such as, for example, permanganates and manganates, salts and oxides of iron, cobalt, copper, molybdenum, tungsten, chromium and silver. and enzymes, preferably catalases.
  • manganese such as, for example, permanganates and manganates, salts and oxides of iron, cobalt, copper, molybdenum, tungsten, chromium and silver.
  • enzymes preferably catalases.
  • the catalyst may be formed in situ in the projection device.
  • a catalyst precursor is mixed with the powdery material composition, with the paste obtained after mixing, or is dissolved in the mixing water or the aqueous solution containing the blowing agent.
  • This precursor is then converted into an active decomposition catalyst of the pore-forming agent based on peroxide, according to certain reaction conditions.
  • the catalyst precursor may especially be chosen from water-soluble manganese (II) salts, such as manganese (II) acetate, manganese (II) sulfate, manganese (II) chloride and manganese nitride (II).
  • These salts can be decomposed, in a basic medium, into insoluble compounds comprising manganese with a +4 oxidation state, such as MnO 2 or MnO (OH) 2 , which are known catalysts for the decomposition of peroxides.
  • the catalyst may in particular be dissolved in the aqueous solution containing the pore-forming agent, if it is maintained at a pH below 5.
  • the amount of catalyst is between 0.1 and 5% by weight relative to the powder composition. Preferably, it is between 0.3 and 2% by weight and even more preferably between 0.5 and 1.5% by weight.
  • the aqueous solution containing the blowing agent is a solution of hydrogen peroxide, a solution of peroxomonosulfuric acid, a solution of persoxodisulfuric acid, a solution of alkaline peroxides, a solution of alkaline earth peroxides or an organic peroxide solution, by for example, peroxoacetic acid or peroxobenzoic acid.
  • the blowing agent is hydrogen peroxide.
  • the concentration of the blowing agent in the aqueous solution is between 1 and 75% by weight, preferably between 3 and 50% by weight and even more preferably between 5 and 40% by weight.
  • the ratio between the flow rate of the composition lost at the outlet of the kneading pump and the flow rate of the aqueous solution comprising the peroxide-based blowing agent introduced into the spraying device varies between 100/1 and 100/30, and preferably between 100/2 and 100/15.
  • the concentration of pore-forming agent in the aqueous solution the more it is necessary to increase the rate of introduction of this solution into the device to have the desired expansion.
  • the peroxide concentration in the aqueous solution is about 35% by weight, the rate of introduction of the solution can be relatively low and the ratio between the rate of composition wasted and the rate of introduction. of the aqueous solution may be less than 100/3.
  • the aqueous solution is less concentrated in peroxide, for example contains 8 mol% of peroxide, the flow rate should be increased and the ratio between the flow rates will be greater than 100/10.
  • the method according to the present invention advantageously makes it possible to spray a lightened material by expansion whose density is less than 400 g / l.
  • the mixing is carried out in the mixing pump (2) by introducing the composition in pulverulent form into the pipe (8) and the mixing water in the pipe (9).
  • the aqueous solution containing the peroxide-based pore-forming agent is introduced into the outlet pipe (3) of the mixing pump (2), which constitutes the mixing step, the catalyst or its precursor having been introduced indifferently with one of the constituents as described above.
  • the aqueous solution containing the peroxide-based pore-forming agent is introduced directly into the feed pipe (9) for entering the mixing water into the mixing pump (2).
  • the composition comprising the hydraulic binder is introduced in pulverulent form through line (8) into the mixing pump where all of these constituents are homogenized.
  • a solution containing the catalyst or its precursor is introduced into the pipe (3) via a pipe (10).
  • the composition in pulverulent form comprising the hydraulic binder is introduced into the mixing pump via the pipe (8).
  • the mixing takes place in the pump with the water introduced via the feed pipe (9).
  • the solution containing the blowing agent is introduced into the kneading pump via line (5).
  • the solution containing the decomposition catalyst or its precursor is introduced directly via the pipe (10) into the outlet pipe (3) of the mixing pump.
  • the composition is mixed upstream of the mixing pump (2).
  • the aqueous solution containing the peroxide-based pore-forming agent is introduced into the outlet pipe (3) of the mixing pump (2).
  • the catalyst or its precursor is introduced indifferently with one of the constituents as previously described.
  • the composition is mixed upstream of the mixing pump (2).
  • the aqueous solution containing the pore-forming agent based on peroxide is introduced directly into the mixing pump (2).
  • the catalyst is then introduced at the outlet pipe (3) of said pump, through the pipe (10).
  • the present invention also relates to a spraying device on a support of a lightweight material by pump expansion used to implement the method described above.
  • the device further comprises a static mixer (7) located in the outlet pipe (3) of the pump.
  • a static mixer (7) located in the outlet pipe (3) of the pump.
  • the introduction line (5) of the aqueous solution containing the peroxide-based pore-forming agent opens into the outlet pipe (3) of the mixing pump (2) at the static mixer ( 7).
  • the present invention also relates to the use of such a device for applying wall or floor mortars.
  • the content of each of the constituents is given in% by weight relative to the total composition.
  • a dry mortar composition comprising the following components is carried out with a peroxide decomposition catalyst precursor.
  • a peroxide decomposition catalyst precursor 88.75% Portland cement CEM 52.5 R (Heidelberg Cement, Schelklingen) 10% glass microspheres (Q-CEL 7014, Potter Industries LLC) 1% manganese sulfate monohydrate (catalyst precursor) 0.2% cellulose ether (DOW 267) 0.05% surfactant (Hostapur OSB).
  • the process is carried out according to the Figure 1A .
  • the mixture (12) of the dry mortar composition and the catalyst precursor and the mixing water are sent to the M-Tec M100 mixing pump (11) each at a flow rate of 100 kg / h.
  • the resulting mixture obtained is pumped continuously with a pumping rate of 200 kg / h.
  • the density of the fresh mortar leaving the spray nozzle is 920 g / l.
  • the line containing an aqueous solution of 8.5% hydrogen peroxide is opened and the aqueous solution is introduced continuously at the end of the nozzle at a static mixer with a flow rate of 20 kg / h.
  • the mortar composition expands immediately and the lightened mortar thus obtained has a density of 260 g / l.
  • a stream of compressed air is introduced through the pipe (6) and a layer of 8 cm thick mortar lightened by stable expansion is projected on the wall.
  • a dry mortar composition comprising the following components is carried out with a peroxide decomposition catalyst precursor.
  • a peroxide decomposition catalyst precursor 84% white cement (CPA CEM1 52.5N Calcia) 15% perlite 0/1 0.7% manganese acetate (catalyst precursor) 0.25% cellulose ether (Tylose MH100000P6) 0.05% surfactant (Ufapore TP808)
  • the process is carried out according to the Figure 2A .
  • the dry mortar composition to which the catalyst precursor was added was spotted (21 kg dry mortar and 30 kg water) in a batch type mixer (M-Tec CM) separated from the spraying device.
  • the paste thus obtained is sent to an M-Tec P20 pump and pumped at a rate of 540 kg / h.
  • the density of the fresh mortar leaving the spray nozzle is 815 g / l.
  • the line containing a 17% aqueous solution of hydrogen peroxide is opened and the aqueous solution is introduced continuously at the end of the nozzle at a static mixer with a flow rate of 36 kg / h.
  • the mortar composition expands immediately and the lightened mortar thus obtained has a density of 250 g / l.
  • a stream of compressed air is introduced through the pipe (6) and a layer of 8 cm thick mortar lightened by stable expansion is projected on the wall.
  • a solution comprising 50% water, 5% manganese acetate, 5% sulfuric acid and 40% of a 35% solution of hydrogen peroxide is prepared (pH maintained at 4).
  • the process is carried out according to the Figure 1A .
  • the pumping capacity of the pump is 22 l / min.
  • the density of the fresh mortar leaving the spray nozzle is 560 g / l.
  • the pipe containing the aqueous solution of hydrogen peroxide is opened and is introduced at a rate of 20 kg / h into the output pipe of the mixing pump, the density of the mortar extracted from the nozzle decreases until at 400g / l.
  • a dry mortar composition comprising the following components is carried out with a peroxide decomposition catalyst precursor.
  • a peroxide decomposition catalyst precursor 72.75% Portland cement (CEM 52.5 Scheklingen) 16% silica airgel (Cabot Nanogel) (2 l / kg) 10% redispersible powder (Vinapas RE 5044) 1% manganese acetate (catalyst precursor) 0.2% cellulose ether (DOW 267) 0.05% surfactant (Hostapur OSB).
  • This composition is mixed with water in a batch mixer (M-Tec CM) separated from the spraying device.
  • the paste thus obtained is sent to an M-Tec P20 pump and pumped at a rate of 540 kg / h.
  • the density of the fresh mortar leaving the spray nozzle is 710 g / l.
  • the process is carried out according to the Figure 2A .
  • the pipe containing an aqueous solution of hydrogen peroxide (concentration of 35%) is opened and this solution is introduced at the end of the nozzle at a static mixer with a flow rate of 14 kg / h.
  • the mortar composition expands immediately and the lightened mortar thus obtained has a density of 270 g / l.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Catalysts (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
EP13708205.3A 2012-02-15 2013-02-13 Procédé continu de fabrication d'un materiau à base de liant hydraulique allegé par expansion Active EP2822913B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1251381A FR2986790B1 (fr) 2012-02-15 2012-02-15 Procede continu de fabrication d'un materiau a base de liant hydraulique allege par expansion
PCT/FR2013/050292 WO2013121143A1 (fr) 2012-02-15 2013-02-13 Procédé continu de fabrication d'un materiau à base de liant hydraulique allegé par expansion

Publications (2)

Publication Number Publication Date
EP2822913A1 EP2822913A1 (fr) 2015-01-14
EP2822913B1 true EP2822913B1 (fr) 2018-09-05

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Country Status (7)

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EP (1) EP2822913B1 (es)
CN (1) CN104105676A (es)
AR (1) AR089986A1 (es)
BR (1) BR112014018585B1 (es)
ES (1) ES2699952T3 (es)
FR (1) FR2986790B1 (es)
WO (1) WO2013121143A1 (es)

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FR3030504B1 (fr) * 2014-12-23 2017-01-20 Lafarge Sa Procede de fabrication en continu d'une mousse minerale a faible densite
US11578007B2 (en) 2015-09-07 2023-02-14 De Cavis Ag Catalytically active foam formation powder
FR3061221B1 (fr) 2016-12-22 2019-05-31 Saint-Gobain Weber Systeme d'isolation thermique par l'exterieur constitue d'un mortier projete fortement isolant
EP3483131B1 (en) 2017-11-09 2020-12-23 Holcim Technology Ltd Method of production of a mineral foam obtained from a foaming slurry of high yield stress
US11008498B2 (en) * 2018-08-16 2021-05-18 Saudi Arabian Oil Company Cement slurry responsive to hydrocarbon gas
CN109053083B (zh) * 2018-09-26 2020-07-28 济南大学 一种高密实抗渗砂浆
CA3152001A1 (en) * 2019-08-30 2021-03-04 Holcim Technology Ltd Method of production of a mineral foam for filling cavities

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DE4035236C2 (de) 1990-11-06 1996-03-21 Wachter Kg Baustoffwerk Werktrockenmörtel für erhöhten Porengehalt
DE19749350A1 (de) * 1997-11-07 1999-05-20 Maxit Holding Gmbh Verfahren zum Herstellen und Anmachen einer Baustoffmischung sowie Baustoffmischung mit porenbildendem Zusatzstoff
TWI255849B (en) * 2001-09-03 2006-06-01 Grace W R & Co Foamed fireproofing composition and method
AT503801B1 (de) * 2006-05-19 2008-01-15 Manfred Sterrer Leichtbetone bzw. mineralstoffe sowie verfahren zu ihrer herstellung
CN102442794B (zh) * 2006-11-09 2016-10-19 电化株式会社 速凝剂及使用其的喷涂方法
CN101306931A (zh) * 2007-05-19 2008-11-19 李波 一种镁水泥制品混合浆料的膨胀剂和加入方法
DE102008058641A1 (de) * 2008-11-22 2010-05-27 K-Utec Ag Salt Technologies Selbsttätig aufschäumender und aushärtender Mineralschaum
FR2942470A1 (fr) * 2009-02-26 2010-08-27 Weber & Broutin Sa Mortier isolant pulverulent, mortier isolant en couche

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Publication number Publication date
CN104105676A (zh) 2014-10-15
FR2986790A1 (fr) 2013-08-16
BR112014018585A2 (es) 2017-06-20
BR112014018585B1 (pt) 2020-12-15
ES2699952T3 (es) 2019-02-13
FR2986790B1 (fr) 2020-02-21
WO2013121143A1 (fr) 2013-08-22
EP2822913A1 (fr) 2015-01-14
AR089986A1 (es) 2014-10-01
BR112014018585A8 (pt) 2017-07-11

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